cnc milling wooden keycaps - cdn-learn.adafruit.com

CNC Milling Wooden KeycapsCreated by Ruiz Brothers

Last updated on 2021-08-31 10:14:23 AM EDT

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Guide Contents

Guide ContentsOverview

Wooden KeycapsTools & MaterialsBantam Tools Library for Fusion 360CAD Files

Keycap DesignSketch DimensionsSketch ProfilesUser Parameters

Stock CAM SetupMaterial TypeMaterial SizeFacing MaterialFacing OperationsSketch & Model StockFace SettingsSimulatePost Process

Fixture Tool PathsSetup Stock for HolderAdaptive Clearing2D Contour2D PocketSimulate and Post Process

Bottom Keycap Tool PathsStock Setup for Bottom KeycapsAdaptive Clearing2D Pocket2D ContourPattern Tool Path OperationsNew Pattern Set UpSimulate and Post Process

Top Keycap Tool PathsStock Setup for Top KeycapsAdaptive ClearingNew Pattern Set UpSimulate and Post Process

Facing StockInstall and Probe ToolAdd Nitto TapeSecure Stock to Spoil BoardJog ControlsSet Up GCODE in Bantam Tools SoftwareMaterial SetupFace MaterialVacuum Saw DustRemove Stock from BedFace Other SideFinish Facing

Mill FixtureGCode Files for Fixture

© Adafruit Industries https://learn.adafruit.com/cnc-milling-keycaps of 35

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Mill Fixture – 1/8inInstall and Probe 1/32in Flat End MillMill Fixture – 1/32inRemove and Sand Fixture

Mill Bottom KeycapsStock for KeycapsFace Stock for KeycapsStock Setup for KeycapsAdd GCode Files for Bottom KeycapsMilled Bottom KeycapsRemove KeycapsSand KeycapsTest Fit Keycaps on Fixture

Mill Top KeycapsInstall 1/8in ProbeLocate PCB BracketInstall PCB BracketProbe BracketSecure Fixture to Spoil BoardInstall Tape on FixtureInstall KeycapsInstall 1/16in ToolSetup GCode for Top KeycapsMaterial OffsetMill Top KeycapsRemove Top KeycapsTest Keycaps with SwitchesFinish Keycaps


OverviewWooden KeycapsIn this guide you'll learn how to CNC mill keycaps for

mechanical key switches.

This part require a custom fixture in order to machine the

internal and exterior geometry of the keycap.

You'll need to use Fusion 360 to customize the tool paths

and stock for your desktop CNC machine.

Tools & MaterialsFusion 360 (https://adafru.it/UB0) – For personal,

Hobby Use

Bantam Tools Milling Machine (https://adafru.it/Cg-)

Bantam Tool Software (https://adafru.it/IVC)

Alignment Bracket (https://adafru.it/UB1)

1/8in (0.3in cutting length) Flat End Mill



Wood material (https://adafru.it/wb8) (5in x 4in x

1/2in)

Double-sided Nitto Tape (https://adafru.it/UB2) (1in

or 1/2in wide)

Bantam Tools Library for Fusion 360

Download the tool library (https://adafru.it/UB3) from Bantam Tools for Fusion 360.

Reference the documentation (https://adafru.it/UB4) on Bantam Tools website for instructions on how to

install the library into Fusion 360.

CAD Files

Use the link below to download the CAD files. The Fusion 360 file is included as well as a STEP file and

STLs of each part. Use the F360 file and follow along with the guide.

https://adafru.it/UB5

https://adafru.it/UB5


https://learn.adafruit.com//assets/104041


https://www.autodesk.com/products/fusion-360/personal

https://www.bantamtools.com/

https://www.bantamtools.com/software-download

https://www.bantamtools.com/spare-parts/bantam-tools-desktop-pcb-milling-machine-tool-set

https://www.inventables.com/categories/materials/wood-mdf/hardwood

https://amzn.to/3sTnUAn

https://support.bantamtools.com/hc/article_attachments/360100781493/Bantam_Tools_Fusion_360_Tool_Library_11.24.20.tools

https://support.bantamtools.com/hc/en-us/articles/360057624454-Fusion-360-Workflows-Programming-CAM

https://cdn-learn.adafruit.com/assets/assets/000/104/079/original/CAD.zip?1630071029

Keycap DesignThe keycap features a DSA profile with symmetrical sides

and features a concave top surface. The dimensions of

the keycap are designed to fit with Kailh box switches

and Cherry MX compatible switches.

Body Size: 18.5mm x 18.5mm x 8mm

Stem Height: 5mm

Wall Thickness: 2mm

Sketch DimensionsThe keycap was created using a few sketches. The

keycap is extruded using the rectangle from the cap top

base sketch with a 22 degree tapered angle at 8mm tall.

The revolve feature was used with the revolve tip sketch

to create the concave on the top of the keycap. 1mm

fillets were applied to the edges to round them out. The

internal cutout was created with a 5mm extrude using the

base sketch with a 22 degree tapered angle. The stem

was created with another extrude using the smaller

rectangle in the base sketch. The cross was created using

the cross sketch with an extrude.

Sketch ProfilesThe base sketch features several rectangle profiles for

creating the holding fixture and the keycap. This was set

up so the keycap is centered with the fixture. Sketch

dimensions show the various sizes of the profiles. Modify

the dimension if you'd like to create a bigger or smaller

holding fixture.





User ParametersVariables were used in sketch dimensions to make

adjustments easier. The capOuter parameter defines the

width and height of the bottom keycap model. The

capSpacing parameter is used to define the spacing

between the rectangular pattern. The capInner is used to

create the internal square of the keycap. The holderPad

parameter is used to create an additional gap along the

edge of the holding fixture. The capSize parameter is

used to define the width and height of the top keycap

model.



Stock CAM SetupMaterial TypePick your desired material by considering the various

types of wood. In this project, hardwoods such as cherry,

walnut, maple and purple heart were machined using with

the same feeds and speeds with great success and

repeatability.

Material Size

When determining material size, it's good to consider the CNC machines spoil board. It's good practice to

cut your stock down so it's slightly smaller than the maximum build volume.

Workable Build: 139mm x 114mm

Stock Size: 126mm x 101mm x 13mm

3x4 Keycap Holding Fixture: 120mm x 91mm x 10mm

Facing Material

Measure the thickness of your stock to determine how much material will need to be removed. If the

stock is not even, it's good practice to surface both sides of the stock.

Facing Operations

Consider using a Face operation to get your stock to the desired thickness. A facing operation removes

all material from the top of stock to top of model. This produces a quick part facing to prepare raw stock

for machining.



Sketch & Model StockIn the design workspace, create a sketch and use the 2-

point rectangle to draw out a shape. While drawing, enter

the height and width values to specify the size of the

rectangle. Use the tab key to switch between the two

dimension text inputs. Click finish sketch when finished.

Click on the rectangle to highlight the profile and use

Extrude (hotkey E) then enter the thickness of the stock.



Face SettingsIn the manufacturing workspace, Press the S hotkey to

summon the shortcuts menu. Type "Face" and press

return to select.

Under the Tool section, click on the Select button and

choose your desired tool. Here we're using a 1/8in flat end

mill.

Under Feed & Speed, reference the surface speed,

cutting feed rate, and plunge feed rate values.

Select the Heights icon in the tabs menu and reference

the Bottom Height values.

Select the Passes icon in the tabs menu and click the

checkbox to enable Multiple Depths. Reference the

values under the Maximum Stepdown.

Click OK to append and save settings.





SimulateUse the shortcuts menu (hotkey "S") and type "simulate"

then press return to select. Click the "Play" icon to run the

simulation. The tool will animate and go through the

operation. If it looks good to you, click the "Close" button.

Post ProcessRight-click on the Face operation in the Browser panel

and select Post Process. Under the Post section, click the

dropdown and choose Bantam Tools. Under the

Name/number section, type a desired file name for the

Gcode file (i.e 1-8-facing). Click on the folder icon under

the Output Folder section and navigate to a desired

folder for saving the GCode file. Click the POST button to

save and close the window.




Fixture Tool PathsSetup Stock for HolderIn the design workspace, isolate the Holder component

using the eye icon to hide the other components.

In the manufacture workspace, create a new Setup using

the icons in the top menu or the shortcuts menu.

Select the dot on the top surface of the lower left corner

of the stock preview. In the Stock tab, reference the

values in the Stock Offset sections.

Adaptive Clearing In the manufacture workspace, click on the Adaptive

Clearing icon in the top 3D menu or use the shortcuts

menu.

Click on the Select button in the tool section and choose

the 1/8in flat end mill.

Under the Feed & Speed section, reference the values.

Click on the Geometry tab and select Bounding Box

under the Machining Boundary in the Geometry section.

Select Tool Outside boundary under the Tool

Containment section.

Click on the Passes tab and change the Maximum

Roughing Step Down. Click the checkbox to disable the

Stock To Leave section.




2D ContourClick on the 2D contour icon in the top menu or the

shortcuts menu.

Click on the select button in the tool section and choose


Under the feed & speed section, reference the values.

Click on the Geometry tab and click on the bottom edge

of the holder. This should highlight the edge blue.

Click on the Heights tab and choose "Selection" under the

Top Height section. Then, click on the top surface of the

holder to highlight it blue.

Click on the Passes tab and click to enable the Multiple

Depths. Change the Maximum Roughing Step Down to

the values in the screenshot. Make sure Stock To Leave is

disabled.





2D PocketClick on the 2D pocket icon in the top menu or use the

shortcuts menu.

Click on the section button the tool section and choose


Under the feed & speed section, use the same values as


Click on the Geometry tab and click on top surface of the

four holes in the model.


Depths. Change the maximum roughing step down to the

values in the screenshot. Make sure Stock To Leave is

disabled.

Simulate and Post Process

Reference the previous CAM setup to simulate the operations. If everything looks good, proceed to Post

Process the GCode files. You have the option to select multiple operations in the Browser. For example,

the Adaptive Clearing and 2D Contour operations use the same tool so this could be posted as a single

GCode file.




Bottom Keycap Tool PathsStock Setup for Bottom KeycapsIn the design workspace, isolate the caps bottom

component using the eye icon to hide the other

components.



Orbit around the model of the bottom keycap so the

internal geometry is facing up right. Select the dot on the

top surface in the lower left corner of the model. Click on

the colored arrows to reposition the X,Y and Z axis so

they match up with the screenshot. In the Stock tab,

reference the values in the Stock Offset sections.

Adaptive ClearingIn the manufacture workspace, click on the Adaptive


menu.



Under the Feed & Speed section, use the same values as


Click on the Geometry tab and select Bounding Box

under the Machining Boundary in the Geometry section.

Select Tool Outside boundary under the Tool

Containment section.








2D PocketClick on the 2D pocket icon in the top menu or use the

shortcuts menu.

Click on the section button the tool section and choose


Under the feed & speed section, use the same values as


Click on the Geometry tab and click on bottom surface of

the cross in center the model.


Depths. Change the maximum roughing step down to the

values in the screenshot. Make sure Stock To Leave is

disabled.




2D ContourClick on the 2D contour icon in the top menu or the

shortcuts menu.

Click on the select button in the tool section and choose


Under the feed & speed section, reference the values.

Click on the Geometry tab and click on the bottom edge

of the keycap model. This should highlight the edge blue.


Depths. Change the Maximum Roughing Step Down to

the values in the screenshot. Make sure Stock To Leave is

disabled.

Pattern Tool Path Operations

With the tool paths now set up, you can use the pattern feature in the Manufacturing workspace to

duplicate the operations.




New Pattern Set UpSince each operation requires a different tool, each

operation will need to be a separate pattern.

Right-click on the first operation (1/16in Adaptive Clearing)

and select Add to New Pattern from the menu.

Under Direction 1, click the Edge button and select one of

the edges in the model that is in the desired axis.

Under Spacing for Direction 1, type in 28.5mm.

Under Number of instances 1, type in 4.

Press OK button to accept and save.

Repeat this process for the 2D Pocket and 2D contour.









GCode file.


Top Keycap Tool PathsStock Setup for Top KeycapsIn the design workspace, isolate the caps top component

using the eye icon to hide the other components.



Select the dot on the top surface in the lower left corner

of the stock preview. In the Stock tab, select Fixed Size

Box under the Mode section. Reference the values for the

Width(X), Depth(Y), Height(Z) and set the model positions

to Center.

Adaptive ClearingIn the manufacture workspace, click on the Adaptive


menu.



Under the Feed & Speed section, use the same values as









New Pattern Set UpOnly a single operation is used for the Top of the keycap

so you may use a single pattern for the Adaptive Clearing

operation.

Right-click on the 1/16in Adaptive Clearing in the browser

and select Add to New Pattern from the menu.

Under Direction 1, click the Edge button and select one of

the edges in the model that is in the desired axis.

Under Spacing for Direction 1, type in 28.5mm.

Under Number of instances 1, type in 4.

Press OK button to accept and save.





GCode file.



Facing StockInstall and Probe ToolIn the Bantam Tools software, click on the JOG icon. In

the Jog Milling Bed dialog window, click on Install Tool.

Walk through the tool installation process. Use the 1/8in

flat end mill. This tool will be used for facing our stock.

Optionally use a fan bit to blow away any sawdust during

the milling operations.

Add Nitto TapeTo secure the stock to the spoil board of the CNC, apply

strips of NITTO tape to one of the surfaces. Ensure the

surface is clean of any dust or debris. Try to cover most of

the surface and avoid overlapping the tape.

Secure Stock to Spoil BoardPlace the stock over the spoil board with the lower left

corner lined up. With the stock lined up, firmly apply

pressure to secure the stock to the spoil board.





Jog ControlsIf you find it difficult to get your hands in the machine, use

the Jog controls to move the spoil board. In the Bantam

Tools software, click on the JOG icon. Under Spindle

Control, switch from STEP to JOG. Use the X and Y

buttons to move the bed. Use the Z buttons to move the

spindle up or down. Click and hold to make continuous

movements.

Set Up GCODE in Bantam ToolsSoftwareIn the Bantam Tools Software, click on the Initial Setup

tab. Click on the blue button, OPEN FILE. Browse and

select the Gcode file for facing the material.

Under the milling tools section, click on the dropdown

menu and select the 1/8" Flat End Mill from the list.

Material SetupClick on the Material Setup tab. Under the Material Size

section, enter your stocks dimensions in the X,Y and Z

input fields.

Under Material Placement, update the Material Offset Z

to 0.2mm (This is the thickness of the Nitto tape).





Face MaterialDouble check all of the settings are updated. Click on the

Summary Run Job tab. Under the Gcode file section, click

on the Mill Single File button.

Watch the CNC machine carefully and check periodically

to make sure everything runs as expected.

Vacuum Saw DustOnce the facing operation is complete, remove the

windows and vacuum up all of saw dust and debris. Use

the Jog controls to get to all of the nooks and crannies.

Remove Stock from BedApply alcohol to the spoil board using a squeeze bottle.

Allow the alcohol to soak into the wood and tape for a

half of a minute. Use a palette knife or spatula to get

under the stock. Gently pray the stock off of the spoil

board.

Peel and remove the tape from the surface of the stock.

Use paper towels to clean up the spoil board.





Face Other SideWith the first side now faced, it's time to do the other side!

In the Bantam Tool software, update the material size.

Under Z, subtract 1.5mm from your stocks thickness. In

this case, the stock was 13mm. The new thickness is now

11.5mm (13 - 1.5).

Follow and repeat the process to face the other side of

the stock.

Finish Facing

Once the second side has been faced, update your material size once more. The stock should now be

10mm. Leave the stock secured to the spoil board.

The next set of Gcode files will create the 1x4 fixture for holding the keycaps.

Leave the stock secured to the spoil board!

Ensure the material thickness is updated to 10mm.

Proceed to the next page when ready.�




Mill FixtureGCode Files for FixtureIn the Bantam Tools software, remove the facing gcode.

Click the three dots icon in the blue bar of the GCode file.

Click Remove to delete.

Click Open File and choose the GCode file for the 1x4

holder with the 1/8in flat end mill. Under the milling tools

section, choose the 1/8in flat end mill from the list.

Click Open file again and choose the GCode file for the

1x4 holder with the 1/32 flat end mill. Under the milling

tools section, choose the 1/32in flat end mill from the list.

Mill Fixture – 1/8inIn the Bantam Tools software, click on summary run job.

Under the 1/8in GCode file, click Mill Single File when

ready.

With the stock still secured to the spoil board and the

1/8in already installed, proceed to mill the 1/8in GCode

file.

When complete, use the vacuum to clean up the saw dust

and debris. DO NOT remove the stock yet. Proceed to

install the 1/32in flat end mill.

Install and Probe 1/32in Flat End MillIn the Bantam Tools software, click on the JOG icon. In

the JOG dialog window, click Install Tool.

Wipe away any dust from the available space on the spoil

board.

Install the 1/32in flat end mill and walk through the

installation process.





Mill Fixture – 1/32inIn the Bantam Tools software, click on summary run job.

Under the 1/32in GCode file, click Mill Single File when

ready.

When complete, use the vacuum to clean up any saw dust

and debris.

Remove and Sand FixtureUse alcohol and a palette knife to remove the fixture from

the spoil board.

Allow the alcohol to soak into the bottom of the fixture.

Use the Jog controls to move the spoil board and spindle

out of the way so you can get a better handle on the

material.

The surfaces of the fixture might be rough and will need

to be sanded down. Use 220 grit sand paper to smooth

out the surfaces in the fixture.

The screenshots in this section are of an early prototype of the fixture. This prototype used a 3x4

layout. The 1x4 fixture requires less material and results in faster machining time.�





Mill Bottom KeycapsStock for KeycapsGet stock prepped and ready for milling. Take a moment

to measure and check if the surface needs to be faced on

both sides.

Depending on the size of the stock, you may want to

create a new GCode file for facing your material in Fusion

360. Reference the Stock CAM setup page.

To make 4x keycaps, our stock was cut to these

dimensions:

127mm x 49mm x 13mm

Face Stock for KeycapsProceed to face the stock material for the keycaps using

the 1/8in flat end mill. Reference the previous pages if you

need.

This stock material was even on both sides. Only the top

surface of the stock will need to be faced.

Remember to vacuum up any saw dust and debris after

every job.

Stock Setup for KeycapsIn the Bantam Tools software, update the stock

dimensions in the Material Setup tab under the Material

Size section. Note, the material thickness is set to 8mm

because the facing operation has already been

completed. Double check the material offset Z is set to

0.2mm (The thickness of the nitto tape).

The stock material will need resurfaced to be 8mm thick in order to properly mill the bottom and

top keycaps.�





Add GCode Files for Bottom KeycapsIn the Bantam Tools software, click on the Initial Setup

tab. Click the Open File button to browse and locate the

three GCode files for milling the bottom keycaps.

Under Milling Tools, use the dropdown menu to select

and choose the corresponding tool for each GCode file.

The bottom keycap GCode files will use the following

tools.

1/8in Flat End Mill – 2D Contours

1/16in Flat End Mill – Adaptive Clearing

1/32in Flat End Mill – 2D Pockets

Milled Bottom KeycapsProceed to mill the three GCode files.

Start with the 1/16in flat end mill to do the adaptive

clearing.

Proceed to mill the 2D pockets using the 1/32in flat end

mill.

Complete the job with the 1/8in flat end mill to do the 2D

contours.

Remove KeycapsVacuum any saw dust and debris from the spoil board

and build area.

Use alcohol to remove the keycaps from the spoil board.

Peel away the nitto tape from the keycaps and spoil

board.





Sand KeycapsThe keycaps may have burrs along the edges. Use 220

grit sand paper to smooth out any rough edges.

Test Fit Keycaps on FixturePlace the keycaps onto the fixture to test fit the

tolerances.

The keycaps should easily press fit onto the fixture.

Test fit each of the keycaps.

Remove all of the keycaps when ready to mill the top side

of the keycaps.





Mill Top KeycapsInstall 1/8in ProbeWhen installing the PCB bracket, use the 1/8in probe.

In the Bantam Tools Software, click on the Jog icon. In the

Tool Install dialog, select the 1/8in Diameter Probe from

the list.

If you don't have a 1/8in probe, you can use the 1/8in flat

end mill. Install the 1/8in flat end mill upside down so the

blunt flat tip touches the bed.

Locate PCB BracketIn the Bantam Tools software, click on the Initial Setup

tab. Under the Brackets and Accessories section, click on

the LOCATE button under the PCB Bracket title.

Read and follow the Locate Bracket dialog.

Remove any material from the spoil board. Wipe the

surface down with a paper towel and alcohol.

Proceed to install the PCB bracket onto the spoil board.





Install PCB BracketThe PCB bracket for the Bantam Tools PCB milling

machine uses 3x M3 screws to secure it to the spoil

board.

Place the PCB bracket over the spoil board and line up

the mounting holes. Use an M3 wrench to fasten and

secure the bracket to the spoil board.

When installation is complete, proceed to click the NEXT

button in the Locate Bracket dialog window.

Probe BracketThe spindle will lower and probe the various edges of the

PCB bracket with the 1/8in probe.

Secure Fixture to Spoil BoardUse double-sided nitto tape to secure the fixture to the

spoil board.

Use several strips of tape to cover the bottom surface of

the fixture.

Place the fixture onto the spoil board with the lower left

corner lined up with the PCB bracket.

Firmly apply pressure to secure the fixture to the spoil

board.





Install Tape on FixtureLay down two strips of double-sided NITTO tape on the

top surface of fixture. Reference the image for best

placement.

This tape is necessary for securing the bottom keycaps to

the fixture. Without the tape, the keycaps will lift during

the top side milling process.

Install KeycapsPlace the bottom keycaps onto the fixture.

Firmly apply pressure to each of the keycaps to secure

them to the fixture.

Install 1/16in ToolIn the Bantam Tools software, Click on the JOG icon. In

the Jog Milling Bed dialog window, click on the Install

Tool button.

Get the 1/16in flat end mill tool ready to install.

This will be used to mill all of the tops of the keycaps.





Setup GCode for Top KeycapsIn the Bantam Tools software, click on the Initial Setup

icon.

Click the OPEN button and select the GCode file for the

top keycaps.

Under the GCode file section, click on the dropdown

menu and select the 1/16in flat end mill from list.

Material OffsetClick on the Material Setup icon. Under the material

placement section, update the Z input under the Material

Offset Z section. Enter 5.4mm into the text box.

Ensure the Align To Spoil Board section is set the LEFT.

Mill Top KeycapsWhen ready, click on the Summary Run Job icon. Under

the top keycap GCode file, click the Mill Single File

button.





Remove Top KeycapsApply alcohol to the top surface of the tape.

Allow the alcohol to soak into the tape to soften up the

adhesive.

Use a palette knife or spatula to remove the keycaps from

the fixture.

Gently slide the palette knife or spatula underneath the

keycaps.

Test Keycaps with SwitchesUse 220 grit sand paper to remove any excess and

smooth out the bottom surface of the keycaps.

Test fit the keycaps by press fitting them onto a Kailh Box

mechanical key switch.

Finish KeycapsOptionally use a finish or stain to the finish your keycaps.

Congrats! You have successfully milled Keycaps out of

wood.

Now you can install them onto your favorite keyboard or

macropad.

Take care and be cautious when removing keycaps from the fixture. Be careful not to break the

keycaps when removing from the fixture.�





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